Method and apparatus for processing large square hay bales into smaller recompressed bales

ABSTRACT

An apparatus is provided for processing large hay bales of approximately 750 kg to produce smaller recompacted manageable units to facilitate shipping in containers. The apparatus provides means for cutting the bales into at least two slabs, preferably three slabs, and means for cutting these slabs into two approximately equal pieces. Means are provided for each piece to be recompressed, strapped and cut again to provide units having an approximate weight of 35 kg.

This application is a divisional of U.S. Ser. No. 09/471,235 filed Dec.23, 1999 U.S. Pat. No. 6,339,986.

FIELD OF INVENTION

This invention relates to compressed forage products, and in particular,to an apparatus for processing large square bales of hay into smaller,recompressed bales.

BACKGROUND OF INVENTION

There is a growing international market for recompressed hay,particularly in Japan and other Asian rim countries. Freight is one ofthe biggest costs in exporting hay overseas. Shipping is usually done incontainers, which have a maximum weight limit. Freight is based on thenumber of containers, and so to minimize freight the container must beloaded to the maximum weight allowable. A typical hay bale, whichconsists of loose field hay which has been compressed once and strappedto form a bale, is too bulky to be transported overseas economically.Therefore, hay bales are commonly recompressed into smaller, denserbales before shipping.

Traditional recompression techniques were limited to small hay bales(approximately 35 to 40 kg; 16-18 in×16 in×48 in), e.g. U.S. Pat. No.5,249,350. However, balers which produce large square bales(approximately 750 kg; and with approximate dimension of 48 in×52 in×96in), have become increasingly popular, due to the increased efficiencyof bale production. In particular, large square bales cost less inmaterials and man hours to produce, and are more efficiently handled andtransported across land to export packaging facilities. These largesquare bales must be processed into smaller, denser bales beforeshipping, to reduce the costs of freight. It is also important that thebales be processed into smaller, more manageable units, because endusers in Asian rim countries generally lack the necessary equipment tohandle large, heavy bales. However, traditional recompression techniquesare not capable of handling the immense size of large square bales.Accordingly, there is a need for a method of processing large squarebales into a product that maximizes container weight, yet is lightenough to be readily handled by the end user, without automatedequipment.

The invention seeks to provide an apparatus for processing a largesquare hay bale into recompressed units, comprising in combination: afirst cutting means for making at least one cut through the bale toproduce at least two slabs of approximately equal size; a separatingmeans for separating the slabs, adjacent to the first cutting means; abale support, adjacent to the separating means; a compression chamberfor recompressing the slabs, adjacent to the bale support means; a firstmoving means for moving the slabs along the bale support means and intothe compression chamber; a second moving means for moving the slabs outof the compression chamber.

An advantage of the apparatus is that it efficiently processes a largesquare bale into smaller, denser bales, which are more cost-effectivefor overseas transport, and which may be more easily handled byend-users without automated equipment. A further advantage of theapparatus is that it produces multiple recompressed bales with eachcycle of the recompression chamber, which allows for greater efficiencyof production. A still further advantage of the apparatus is that itproduces recompressed bales of uniform weight and good appearance.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the invention will be obtained by consideringthe detailed description below, with reference to the following drawingsof embodiments of the present invention in which:

FIGS. 1A to 1E are perspective views showing the processing of a largesquare hay bale using the apparatus of this invention.

FIG. 1A illustrates the step of making two horizontal cuts in the largesquare bale, to create three horizontal slabs.

FIG. 1B illustrates the step of making a vertical cut in the slab, tosection off a unit having a desired weight.

FIG. 1C illustrates the unit, before recompression.

FIG. 1D illustrates the step of recompressing and strapping the unit.

FIG. 1E illustrates the step of cutting the recompressed unit into thedesired end products, having the desired weights.

FIGS. 2A to 2E are perspective views showing an alternative embodimentof the present invention, for processing a large square bale ofdifferent dimension than that illustrated in FIGS. 1A to 1E.

FIG. 2A illustrates the step of making one horizontal cut in the largesquare bale, to create two horizontal slabs.

FIG. 2B illustrates the step of making a vertical cut in the slab, tosection off a unit having a desired weight.

FIG. 2C illustrates the unit, before recompression.

FIG. 2D illustrates the step of recompressing and strapping the unit.

FIG. 2E illustrates the step of cutting the recompressed unit into thedesired end products, having the desired weights.

FIG. 3 is a top plan view of the apparatus.

FIG. 4 is a side view of another section of the apparatus wherein a baleis forced against a stationary horizontal knife.

FIG. 5 is a front view of a vertical knife for use in the apparatus.

FIG. 6 is a schematic front view of an elevator; and

FIG. 7 is a cross-sectional view of a compactor of the embodiment takenalong the line 7—7 of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1A to 1E and 2A to 2E, an apparatus for processing alarge square hay bale 21 according to the present invention is used asfollows. At least one horizontal cut 20 is made through the bale toproduce slabs 22 of approximately equal size. A typical large squarebale has a plurality of binding straps, and the cut 20 is made betweenstraps in a direction substantially parallel to the direction of thestraps. The slabs 22 are then separated from each other and moved alonga bale support towards a compression chamber. A vertical cut 24 is madethrough a slab 22 to produce a unit 22 a of a desired weight to fill thecompression chamber. The unit 22 a is compressed in the compressionchamber to provide a compressed unit 26, removed from the compressionchamber, and strapped using a plurality of straps 28 in a spaced apartrelationship, such that a vertical cut 30 may be made between the straps28 to produce an end product 32 of a desired weight.

It will be appreciated that the apparatus is suitable for large squarebales of various sizes, and may also be used for processing smallerbales, with appropriate adjustments to the number of cuts. For example,in FIGS. 1A to 1E, a large square bale having the dimensions of 96 in×52in×48 in, is processed by making two horizontal cuts 20 through the haybale to produce three slabs 22 of approximately equal size. A verticalcut 24 is made through a slab 22 to produce a unit 22 a having a desiredweight. After compression and strapping, two vertical cuts 30 are madethrough the compressed unit 26 to produce an end product 32 havingapproximate dimensions of 16 in×17.5 in×18 in.

In another embodiment, shown in FIGS. 2A to 2E, a large square balehaving the dimensions of 96 in×36 in×36 in, is processed by making onehorizontal cut 20 through the hay bale to produce two slabs 22 ofapproximately equal size. A vertical cut 24 is made through a slab 22 toproduce a unit 22 a of a desired weight to fill the compression chamber.After compression and strapping, one vertical cut 30 is made through thecompressed unit 26 to produce an end product 32 having approximatedimensions of 16 in×18 in×18 in.

It will be appreciated that one may vary the weight of the end product32 by adjusting the weight of the unit 22 a used to fill the compressionchamber and/or the number of vertical cuts 30 made to the compressedunit 26.

An apparatus comprising a first embodiment of the invention is showngenerally at 90 in FIG. 3 and includes a bale cutter shown at 100 inFIG. 4.

As shown in FIG. 4 a bale 21 is moved into contact with stationaryknives 105. Knife attachment members 101 are secured as by welding toopposed side knife support members 103 adjacent one end of a bale bed102.

Each of the knives 105 has a flat side 106, a bevelled side 107 and acutting edge 108. The knives 105 are spaced apart to define threeapproximately equal compartments having a top edge equipped with apressure plate 115 secured to the side plates 103.

In an alternate embodiment, the cutting device may have only onehorizontal knife or multiple horizontal knives.

A cylinder 109 mounted on a pivot 119 at an end of the bale bed 102remote from the knives 105 has an inner end secured to the side of a ramhead 132. The ram head 132 has upright transversely extending pusherplates 124, 125 and 126 secured thereto as by welding. Spaces 133 and134 are provided at the ends of the plate 125, and are in alignment withthe knives 105 and a space at the outer end of the plate 124accommodates the pressure plate 115.

In operation, a bale 21 is placed on the bale bed 102 and the hydrauliccylinder 109 actuated thereby forcing a bale 21 against the cutting edge108 of the knives 105. The upper side of the bale 21 contacts thepressure plate 115 to minimize deformation of the bale 21. The knives105 can extend into the spaces 133 and 134 to complete the cutting of abale 21 into three slabs 22 which are received on an elevator platformseparating device 200. The elevator platform 200 (as shown more clearlyin FIG. 6) moves between a down position, where it is in alignment withthe bale bed 102, and an up position, where it is in alignment with abale support 202, and is indexed to stop as each of the slabs 22 is inalignment with the bale support 202. A pusher 204 is then activated asone of the slabs 22 is aligned with the bale support 202 and off loadsan upper one of the slabs 22 onto the bale support 202. The pusher 204moves upwardly and rearwardly before descending for the next cycle.

As shown in FIG. 3, the bale support 202 is provided with vertical sides205 and 206 to guide the slab 22. The bale support 202 has a right anglebend at 210 and a pusher 212, similar to pusher 204, engages an end of aslab 22 to move the slab towards a weigh station 220 and a secondcutting knife 225.

FIG. 5 shows a preferred embodiment of part of the invention 90 in whichknife guide members 221 are attached, by welding or similar conventionalmeans, to opposed sides 205 and 206 of the bale support 202. Crossmember 223 is similarly attached to the upper ends 224 of the knifeguide members 221. The knife 225 has a flat side (not shown) and abevelled side 227 meeting at a cutting edge 228, and is mounted oncutting hydraulic cylinders 229 by means of clevises 230 so as to beslidably engaged in guide channels 231. Cutting channel 222 accommodatesthe knife cutting edge 228 when the knife 225 is in the loweredposition.

Referring again to FIG. 3, another pusher means 240, similar to thepusher 204, is preferably provided to move cut slab 22 a in front ofinlet opening 242 of the compression chamber 244. As shown more clearlyin FIG. 7 the compression chamber 244 is provided with guide means 250hingedly attached at the compactor inlet 242. The guide means has a topwall 252 and two side walls 254 and 256. It will be appreciated that theguide means 250 is raised before the cut slab 22 a is moved to thecompression chamber 244. When the cut slab 22 a is in position, theguide means 250 is lowered and a rectangular ram provided with suitablehydraulic means 258 is adapted to move the cut slab 22 a into thecompression chamber 244. The major portion of the compaction orcompression is provided by a hydraulically operated ram 264 which movesparallel to the table 202. A compressed unit 26 is ejected by anejection ram 270 and is positioned in a banding or strapping station.The bale strapping machine 274 moves along the length of therecompressed unit 26 providing straps 28 at the required intervals. Therecompressed unit 26 is not capable of being easily handled withoutmachinery and therefor further subdividing of the recompressed unit 26is carried out in the cutter box 280. A ramp may be sloped downwardlyfrom the strapping machine 274 to the cutter box 280 to feed therecompressed units 26 into the cutter box 280. The cutter box 280 ispositioned to receive recompressed units 26 leaving the strappingstation 274 and has walls 284 to guide the recompressed units 26 ashydraulic rams 290 move the bale slab through at least one verticalknife which divides the recompressed unit 26 into smaller units 32 ofapproximately equal size. In a preferred embodiment, the cutter box 280contains two vertical knives. The vertical cuts are made between thestraps in a direction substantially parallel to the direction of thestraps. A second elevator receives the smaller units 32 after they passthrough vertical knives, and lowers them to the ground, where a movingdevice pushes the smaller units 32 from the second elevator onto theground.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. Method of processing alarge square hay bale, into recompressed units comprising the steps of:(a) making at least one cut through said bale to produce at least twoslabs of approximately equal size: (b) elevating the slabs usingelevator means having a platform which is movable between a downposition, wherein receives the slabs of the bale, and an up position,wherein it is substantially level with a bale support means, and pushingthe slabs one a time from the elevator means onto the bale supportmeans, using a moving means: (c) recompressing said slabs in acompression chamber; and (d) removing said slabs from the compressionchamber, wherein the bale has a plurality of binding straps, and whereinthe cut is made between at least two of the straps in a directionsubstantially parallel to the direction of the straps, and wherein saidcut is made by pushing the bale through at least one stationaryhorizontal knife using a hydraulically actuated plate.
 2. Method ofprocessing a large square hay bale, into recompressed units comprisingthe steps of: (a) making at least one cut through said bale to produceat least two slabs of approximately equal size; (b) elevating the slabsusing elevator means having a platform which is movable between a downposition, wherein it receives the slabs of the bale, and an up position,wherein it is substantially level with a bale support means, pushing theslabs one a time from the elevator means onto the bale support means,using a moving means and moving said slabs along said bale support meansto said compression chamber, (c) recompressing said slabs in acompression chamber; and (d) removing said slabs from the compressionchamber, wherein the bale has a plurality of binding straps, and whereinthe cut is made between at least two of the straps in a directionsubstantially parallel to the direction of the straps, and wherein saidcut is made by pushing the bale through at least one stationaryhorizontal knife using a hydraulically actuated plate.